Web lap splicer

ABSTRACT

Apparatus for splicing the end of a spare roll of web to web being drawn from a depleting roll. The web in use extends past a cutting station and between two sets of spaced nip rollers. The web then extends to a festoon which acts as tension sensing element and a web storage mechanism. The motion of a carriage carrying the moveable festoon rollers operates a brake mechanism for controlling the unwind of the depleting roll. The web from the spare roll extends over a roller and between the first set of nip rollers. Conveyor belts extend between the first and second nip rollers. A piece of double faced pressure sensitive tape is applied to the end of the web to be spliced. When splicing is initiated the nip rolls move together attaching the new web to the running web. A knife then severs the web from the depleting roll. The festoon supplies web at constant tension while the new roll accelerates to line speed.

United States Patent [1 1 Taitel [4 1 May 27, 1975 WEB LAP SPLICER [75] Inventor: Charles M. Taitel, Parsippany, NJ.

1731 Assignee: Compensating Tension Controls Inc., Orange, NJ.

[22] Filed: June 10, 1974 1211 Appl. No.: 477,857

[52] US. Cl. 156/504; 156/157; 156/505; 156/507; 242/584 [51] Int. Cl B65h 19/08 [58] Field of Search 156/157, 504, 505, 507; 242/58.l, 58.3, 58.4

[56] References Cited UNITED STATES PATENTS 3,367,825 2/1968 Cvacho et a1 156/505 3738587 6/1973 Cristiani 156/504 X 3.749634 7/1973 Krause 156/505 Primary ExaminerWilliam A. Powell Attorney, Agent, or FirmGerald Durstewitz [57] ABSTRACT Apparatus for splicing the end of a spare roll of web to web being drawn from a depleting roll. The web in use extends past a cutting station and between two sets of spaced nip rollers. The web then extends to a festoon which acts as tension sensing element and a web storage mechanism. The motion of a carriage carrying the moveable festoon rollers operates a brake mechanism for controlling the unwind of the depleting roll. The web from the spare roll extends over a roller and between the first set of nip rollers. Conveyor belts extend between the first and second nip rollers. A piece of double faced pressure sensitive tape is applied to the end of the web to be spliced. When splicing is initiated the nip rolls move together attaching the new web to the running web. A knife then severs the web from the depleting roll. The festoon supplies web at constant tension while the new roll accelerates to line speed.

13 Claims, 8 Drawing Figures PmErm-w 27 1915 3; 886; 031 SHEET 1 Pmmmmv 1915 3.888031 SHEET 2 FIG.3

WEB LAP SPLICER BACKGROUND OF THE INVENTION The present invention relates to web splicing apparams, and, more particularly, to such apparatus which lap splices the leading end of a full roll of web onto the web drawn from a depleting roll of web.

Web splicers are conventionally used to provide a continuous supply of web by overcoming the interruption resulting from the depletion of a supply roll. Such splicers normally include a splicing unit, a festoon, and spindles for holding the roll of web in use and a spare roll. The festoon includes a moveable carriage which is biased against the web tension by a compressed air cylinder. As the diameter of the supply roll decreases as web is drawn therefrom, the braking action applied to the supply roll to maintain a desired web tension must be gradually decreased. In the past, web splicers have been supplied with devices which adjust the brake in accordance with the supply roll diameter. Such devices however, do not respond to web tension changes from other causes and therefore are not entirely satisfactory. In lap splicers, the splicing unit conventionally includes a single pair of nip rollers. The nip rollers are normally spaced apart and the web extends from the roll in use past a cutting station and between the nip rollers. The end of the web on the spare roll is positioned between the nip rolls and a piece of double faced pressure sensitive tape is at the end of the web on the surface facing the running web. To splice the two webs, the nip rolls are brought together to press the tape against the running web and the running web is severed. The festoon, which acts as a web storage unit, supplies web to the using machinery while the new roll accelarates to line speed.

In order to produce a smooth and secure splice using equipment of the prior art designs, the tape must be accurately placed at the end of the web and the end of the web must be accurately placed with relation to the nip rolls. If the tape is not placed at the end of the web, the loose web end can fold back on itself to form an bstruction which can cause jamming in the web using machinery. If the tape is placed on the web at an angle, the nip rolls may press only a portion of the tape against the running web. Likewise, if the tape strip is placed past the closest point of the two nip rollers, less than the complete width of the tape strip will be firmly pressed against the running web. In either of the leat two instances a weak splice is produced.

SUMMARY OF THE INVENTION In view of the foregoing, it is an object of the present invention to provide an improved splicer for web materials.

Another object is to provide such a splicer which includes an improved tension control arrangement.

Another object is to provide a lap splicer which consistently produces smooth and secure splices.

Another object is to provide such a lap splicer which is simple and easy to operate.

BRIEF DESCRIPTION OF THE DRAWINGS A preferred embodiment of the invention has been chosen for the purposes of illustration and description and is shown in the accompanying drawings forming a part of the specification wherein:

FIG. 1 is a schematic front view of a lap splicer according to the present invention.

FIG. 2 is an end view of the splicing assembly.

FIG. 3 is a sectional side view of the splicer.

FIG. 4 is a rear view of the splicer.

FIG. 5 is a schematic drawing of the pneumatic system controlling the operation of the splicer.

FIG. 6 is a schematic drawing of air cable cylinder pneumatic circuit.

FIG. 7 is a detailed view of a roll brake assembly.

FIG. 8 is a view taken along line 8-8 on FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings, and particularly to FIG. 1, thereof, there is shown a lap splicer which comprises a frame plate 10, a pair of spindles 11 and 12 rotatably mounted on the frame, brake assemblies 13 and 18 for controlling the rotation of the spindles, a splicing assembly 14 is mounted on a plate 15 which is bolted to the plate 10, and a festoon 16 is mounted on the plate 10.

The splicing assembly 14 as shown in FIG. 2, includes a pair of web directing rollers 17 and 19, a pair of leading nip rollers 20 and 21, a pair of trailing nip rollers 22 and 24, a plurality of endless belts 25 of circular cross section extending between the rollers 20 and 22 and between the rollers 21 and 24, a web directing roller 26 below the nip rollers, a double edged knife 27 mounted on a pivoted holder 29, a clamp roller 30 mounted on a pivoted holder 31 and a pair of knife back-up assemblies 32 and 33 positioned between the web directing rollers 17 and 19 and the leading nip rollers.

As shown in FIG. 1, a nearly depleted roll of web 34 having a core 35 is mounted on the spindle 12. The web from the roll 34 passes over the roller 19 and extends (as shown in FIG. 2) downwardly to the roller 26 between the two sets of nip rollers. The position of the roller 19 causes the web to engage the surface of the leading nip roller 21.

A spare roll of web 36 wound on a core 37 is posi' tioned on the spindle 11. The apparatus is prepared for splicing by leading the end of the web over the roller 17 past the assembly 32 and between the leading nip rollers 20 and 21. A piece of pressure sensitive double faced tape 39 is applied at the end of the spare web on the surface facing the running web.

The rollers 20, 21, 22 and 24 are rotatably mounted on shafts 40 by means of bearings 41. As shown in FIGS. 2 and 3, the shafts 40 extend from the plate 15 to a plate 42 which is mounted to the shafts of the rollers l7 and 19 and to the back-up assemblies 32 and 33. The shafts 40 are formed with eccentrically oriented ends portions 44 and 45 which extend through bushings 46 in the plates 15 and 42 respectively. Gears 47 are mounted to the ends of the extensions 44. A gear rack 49 is mounted on the piston rod 50 of a pneumatic actuator 51 which is supported in back of the plate 15 by a bracket 52. The rack 49 engages the gears 47 so that upon extension of the piston rod 50, each of the shafts 40 are rotated about the axis of the eccentric shaft ends 44 and 45 to bring the leading nip rollers 20, 21 and the trailing nip rollers 22, 24 are brought together, Each of the nip rollers 20, 21, 22 and 24 has grooves 53 formed in the surface thereof to receive the belts 25. The grooves 53 have a depth equal to the cross-sectional diameter of the circular belts so that the outer surface of each belt is flush with the surface of the nip rollers. The nip rollers therefore, when brought together, exert pressure along a continuous line upon the webs at the splice.

The knife holder 29 includes a knife holding section 54 and end arms 55 and S6. Shafts 57 and 59 extend from the arms 55 and 56 and are journalled in bearings 60 and 61 set in the plates 15 and 42.

The knife blade 27 is clamped to the bar section 54 by a clamping member 62.

The roller holder 31 comprises a roller holding section 64, an arm section 65 journalled to the shaft 57 by means of a bearing 66, and an arm section 67 journalled to the shaft 59 by means of a bearing 69. The rol ler 30 is rotatably mounted on a shaft 70 which is supported between projections 71 and 72 on the member 64. A bar 73 extends from the projection 71 through a rectangular opening 74 in the plate 15.

A spring 75 extends between a pin 76 inserted in the bar 73 and a pin 77 inserted in the bracket 52.

An arm 79 is mounted on the end of the shaft 57 and is connected to the piston rod 80 ofa pneumatic actuator 81 which is anchored to the frame 10. A knife centering spring 82 is connected between a pin 84 carried by the arm 79 and a pin 85 mounted in the plate 15.

A web roll feeler arm 86 is mounted on a shaft 87 which is journalled in a bushing 89 set in the plate 15. A pair of cams 90 and 91 are mounted on the shart 87 behind the plate 15 and are provided with switch oper ating tabe 93 and 94 respectively. A pneumatic switch 95 mounted on the back face of the plate 15 has an actuating arm engaging the surfaces of the cams 90 and 91. A wheel 97 mounted on the end of the arm 86 rides on the depleting web roll 34. Another pneumatic switch 98 is positioned on the back of the plate 15 to indicate the position of the clamp roller 30. A third pneumatic switch 100 is mounted to the bracket 52 and has an actuating button for engaging the bottom of the gear rack 49. A push button pneumatic switch 102 is mounted on the plate 42.

If the web has a design printed thereon, a photo electric unit 104 (FIG. 1) mounted on the frame 10 is employed to time the splicing operation so that the printed design of the spliced webs is in registration.

When as shown in FIG. 1, the depleting roll is mounted on the spindle 12. the clamp roller is manually positioned against the roller 19 to determine the direction in which the knife as described hereinafter, and the end of the spare roll of web is prepared as previously discussed. The knife is held in a central position by the spring 82 until the actuator 81 is energized. As the roll in use is depleted the arm 86 rotates the shaft 87 rotating the earns 90 and 91. When the roll is substantially depleted, the operating tab 93 operates the switch 95. As shown in FIG. 5, the operation of switch 95 allows pressurized air to flow to a conventional pulse generating valve which, in response to the steady pressure applied thereto, deiivers pressure to the downstream line for only 2 seconds. The pressure pulse from the valve 106 flows through a shuttle valve 107 and through a manually operated valve 108 (bypassing a normally closed solenoid valve 109) to a four way valve 110. The pressure pulse drives the moveable valve member of the valve 110 against a spring 111 to connect air pressure to the nip roll actuator 51 so to retract the piston thereof to drive the rack 49 downwardly and rotate the eccentric shafts 44 to move the nip rollers together. At the same time, the pressure flowing through the valve 110 energizes an actuator 112 to operate the brake assembly 18 to start slowing down the spindle l2 and energizes an actuator 114 to release the brake assembly holding the spindle 11.

In response to the operation of the rack 49, the rollers 20 and 21 move toward each other, and, at the same time, the rollers 22 and 24 move toward each other. When the rollers 20 and 21 meet, the tape strip 39 is pressed against the running web splicing the end of the spare roll to the running web.

As the splice moves from the nip rolls 20 and 21 to downwardly, it is carried between the belts 25 and the lower nip rollers 22 and 24. The belts 25 support the end of the web from the roll 36 so that, if the tape strip 39 is not applied directly to the edge of the web end, the web end is prevented from folding back to increase the thickness ofthe spliced area. The second set of nip rollers 22, 24 again presses both of the webs inwardly against the tape strip 39 to insure a secure splice throughout the length and width of the tape strip. Therefore, if the tape strip is placed across the spare web at an angle, or is initially placed too far into the splicing assembly, so that the first pair of nip rollers does not engage the entire area of the tape, the second pair of nip rollers will complete the splice.

The air switch 100 is normally closed delivering pressure to hold a three way valve 115 in the position shown in FIG. 5. When the rack 49 assumes its lowest position, it opens the air valve 100 interrupting pressure to the valve 115 to allow its spring 116 to drive the valve member to the left connecting air pressure through a four way valve 117 to the actuator 81. The actuator 81 rotates the shaft 57 to drive the knife 27 against the knife backup assembly 33 and sever the web running from the depleting roll 34.

When the 2 second pressure pulse delivered by the valve 106 terminates, the spring 111 of the four way valve 110 moves the valve member thereof to the left to connect pressure to the other side of the piston in the actuator 51. The rack 49 is thus driven upward separating the nip rollers. As the rack 49 moves upward, the switch 100 closes moving the valve member of the valve 115 back to the position shown in FIG. 4 to vent the actuator 81 and allow the spring 82 to return the knife to its central position.

The switch 97 is normally closed to transmit pressure to the four way valve 117 to interconnect the actuator 81 and the valve 115 so as to drive the knife in the direction described above. As the roll 36 of web depletes, a spare roll of web is placed on the spindle 12 and the clamp roller 30 is moved to lie against the roller 17. The bar 73 actuates the air switch 97 to disconnect the pressure delivered therefrom to the valve 117. The valve 117 therefore assumes a position reversing the pressure connection between the actuator 81 and the valve 115 so that on the next splicing operation, the knife is driven against the backup assembly 32.

When the spare roll is placed on the spindle 12, the roll feeler arm 86 is rotated over to engage the roll 36. When the roll 36 is depleted, the tab 94 will operate the switch 95 to start the splicing operation.

Alternatcly, the splicing operation can be initiated manually be operating the push button switch 102. As shown in FIG. 4, the switch 102 is normally open, and, when operated, directs pressurized air through the shuttle valve 107 and the valve 108 to operate the four way valve 110. The push button switch 102 is held in until the knife fires and is then released allowing the pressure in the line to vent and allow the valve 110 to operate so as to open the nip rollers.

When printed web is being used, the photo electric unit 104 is employed to place the design on the space roll in register with the design on the running web. In this instance, the operator prepares the leading edge of the spare web in the manner described before except that the web is cut and taped at a specific location on the design. The valve 108 is manually closed so that pressure cannot reach the valve 110 until the solenoid valve 109 is opened by the operation of the photo cell unit 104. After the manual switch 102 or the web feeler switch 95 is closed, further operation is delayed until a registration mark passes the photo electric unit 104. Passage of the registration mark on the running web activates the unit 104 to energize the valve 109 and admit pressure to the valve 110 to close the nip rollers.

During the splicing operation, and while the spare roll is accelerating to line speed, the festoon 16 (FIG. 1) supplies web to the utilizing machine.

The festoon 16 includes a carriage 120 slideably mounted on a pair of rods 121. A pair of rollers 122, 124 are rotatably mounted on the carriage 120 and a pair of rollers 125, 126 are rotatably mounted on the frame 10. The rods 121 are mounted to the frame by brackets 127. A cable air cylinder 129 is mounted to the frame 10 between the rods 121.

As shown schematically in FIG. 6, the cable air cylinder 129 has a piston 130 therein to which both ends of a cable 131 is attached. The cable 131 passes over a pulley 132 at each end of the cylinder 129 and is attached to the carriage 120.

When the web is slowed down during the splicing operation, the tension in the web draws the carriage toward the right against the pressure acting on the piston 130 in the cylinder 129. The air pressure is supplied to the cylinder 129 through a four way valve 133 from a pressure regulator 134, which maintains the pressure in the cylinder at a constant value. As the carriage moves the piston 130, the regulator 134 unloads air to maintain the pressure constant and thus keep the tension on the web constant as the festoon empties and refills.

When the festoon is filled, the tension on the web is controlled by a brake actuating system including a pulley 135, a cam surface 136 on the carriage which acts upon a roller 137 carried by the pulley 135, pulleys 139 and 140 for actuating the brake assemblies 13 and 18, and a pair of cables 141 and 142 which connect the pulley 135 to the pulleys 139 and 140.

As shown in FIG. 7, the brake assembly 13 includes a brake drum 144 mounted on the spindle 11, a brake band 145, a spring assembly 146 connecting one end of the band 145 to the frame 10, and a crank 147 connected to the other end of the band 145 and mounted on a rotatable shaft 149 which carries the pulley 139. The actuator 114 is positioned so that its shaft 150 en gages the crank 147 when the actuator 114 is energized to operate the brake assembly 13. The brake assembly 18 is identical to the assembly 13 except it is a mirror image, that is, all parts are reversed.

The spring assemblies 146 are adjusted to tension the cables 141, 142 and rotate the pulley 135 to urge the roller 137 against the cam surface 136.

Any changes in tension in the web tends to move the festoon carriage along the bars 121. As the carriage moves, the pulley 135 is rotated by the action of the cam surface 136 against the roller 137 to rotate the pulleys 139, 140. The resulting motion of the crank 147 carried by the pulleys 139, adjusts the force applied to the brake bands 145 and thus re-establishes the desired tension in the web.

During the splicing operation, the carriage moves far to the right thus allowing the pulley to rotate sufficiently to release the brake assemblies 13 and 18.

The four way switch 133 is employed to drive the festoon carriage to the right to simplify threading the web onto the splicer.

It will be seen from the foregoing that the present invention provides an improved lap splicer for web materials which consistently produces smooth and secure splices and which is simple and easy to operate.

What is claimed is:

1. Apparatus for splicing the end of web material from a spare supply roll to web material being drawn from a depleting supply roll comprising in combination first and second leading nip rollers and first and second trailing nip rollers spaced from said leading rollers, each of said first and second rollers being normally spaced apart, at least one of said leading rollers and at least one of said trailing rollers being mounted to be moveable toward the other of said leading and trailing rollers, endless conveyor means extending between said first rollers, second endless conveyor means extending between said second rollers, directing the running web between said conveyor means in close proximity to said second leading roller, means for directing the web from said spare roll between said leading rol lers and in close proximity to said first leading roller, and means for moving said moveably mounted leading and trailing rollers to bring said leading and trailing rollers together so that the spare web and the running web are pressed together to be joined by a piece of tape applied to the spare web.

2. Apparatus according to claim 1 wherein said first and second conveyor means each include a plurality of endless belts.

3. Apparatus according to claim 2 wherein said nip rollers are formed with peripheral grooves for accepting said belts, said grooves beingdimensioned to place the outer surface of said belts flush with the outer surface of said nip rollers.

4. Apparatus according to claim 3 wherein said belts are circular in cross-section.

5. Apparatus according to claim 1 wherein each of said nip rollers are mounted by means of shafts eccen tric with respect to said nip rollers so that rotation of said shafts move each of said leading nip rollers toward each other and move each of said trailing nip rollers toward each other.

6. Apparatus according to claim 5 including gears mounted to said eccentric shafts and a rack gear means engaging said gears to oppositely rotate said first and second nip rollers.

7. Apparatus according to claim 6 including a pivoted knife arm mounted between said running web and said web from said spare roll, first and second shaft means mounting said knife are, actuator means for rotating said knife are in either direction, a clamp roller arm means pivotally mounted on said first and second knife arm shafts, switch means operated by said clamp roller arm means for controlling the direction of operation of said actuator means.

8. Apparatus according to claim 7 including actuator means for driving said rack gear means and switch means responsive to the movement of said rack gear means for operating said knife arm actuator means when said nip rollers move together.

9. Apparatus according to claim 8 including pivoted feeler arm means engaging said depleting web roll, and switch means operated by said feeler arm means for operating said rack driving actuator means when said depleting web roll is effectively depleted.

10. Apparatus according to claim 9 including photo electric means positioned to scan said running web for delaying the operation of said rack driving actuator until a registration mark on the running is detected thereby so that a design printed on the webs is in registration at the splice.

11. Web splicing apparatus comprising in combination a pair of rotatable spindles for holding a roll of web in use and a spare roll of web, a splicing assembly for splicing the web from the spare roll to the web in use when the roll of web in use is depleted. a brake assembly for each of said spindles, a festoon including a carriage subject to linear motion in response to a change in tension on the web, a pulley adjacent said carriage cables connecting said pulley to each of said brake assemblies, means for changing the rotational position of said pulley in response to linear movement of said carriage to adjust said brake assemblies to maintain constant tension on the web.

12. Apparatus according to claim 11 wherein said last-mentioned means includes a cam element on said carriage and a cooperating cam element on said pulley.

13. Apparatus according to claim 12 including an air cylinder biasing said carriage against the tension in the web, and a pressure regulator for maintaining the pressure in said cylinder constant at all times. 

1. Apparatus for splicing the end of web material from a spare supply roll to web material being drawn from a depleting supply roll comprising in combination first and second leading nip rollers and first and second trailing nip rollers spaced from said leading rollers, each of said first and second rollers being normally spaced apart, at least one of said leading rollers and at least one of said trailing rollers being mounted to be moveable toward the other of said leading and trailing rollers, endless conveyor means extending between sAid first rollers, second endless conveyor means extending between said second rollers, directing the running web between said conveyor means in close proximity to said second leading roller, means for directing the web from said spare roll between said leading rollers and in close proximity to said first leading roller, and means for moving said moveably mounted leading and trailing rollers to bring said leading and trailing rollers together so that the spare web and the running web are pressed together to be joined by a piece of tape applied to the spare web.
 2. Apparatus according to claim 1 wherein said first and second conveyor means each include a plurality of endless belts.
 3. Apparatus according to claim 2 wherein said nip rollers are formed with peripheral grooves for accepting said belts, said grooves being dimensioned to place the outer surface of said belts flush with the outer surface of said nip rollers.
 4. Apparatus according to claim 3 wherein said belts are circular in cross-section.
 5. Apparatus according to claim 1 wherein each of said nip rollers are mounted by means of shafts eccentric with respect to said nip rollers so that rotation of said shafts move each of said leading nip rollers toward each other and move each of said trailing nip rollers toward each other.
 6. Apparatus according to claim 5 including gears mounted to said eccentric shafts and a rack gear means engaging said gears to oppositely rotate said first and second nip rollers.
 7. Apparatus according to claim 6 including a pivoted knife arm mounted between said running web and said web from said spare roll, first and second shaft means mounting said knife are, actuator means for rotating said knife are in either direction, a clamp roller arm means pivotally mounted on said first and second knife arm shafts, switch means operated by said clamp roller arm means for controlling the direction of operation of said actuator means.
 8. Apparatus according to claim 7 including actuator means for driving said rack gear means and switch means responsive to the movement of said rack gear means for operating said knife arm actuator means when said nip rollers move together.
 9. Apparatus according to claim 8 including pivoted feeler arm means engaging said depleting web roll, and switch means operated by said feeler arm means for operating said rack driving actuator means when said depleting web roll is effectively depleted.
 10. Apparatus according to claim 9 including photo electric means positioned to scan said running web for delaying the operation of said rack driving actuator until a registration mark on the running is detected thereby so that a design printed on the webs is in registration at the splice.
 11. Web splicing apparatus comprising in combination a pair of rotatable spindles for holding a roll of web in use and a spare roll of web, a splicing assembly for splicing the web from the spare roll to the web in use when the roll of web in use is depleted, a brake assembly for each of said spindles, a festoon including a carriage subject to linear motion in response to a change in tension on the web, a pulley adjacent said carriage cables connecting said pulley to each of said brake assemblies, means for changing the rotational position of said pulley in response to linear movement of said carriage to adjust said brake assemblies to maintain constant tension on the web.
 12. Apparatus according to claim 11 wherein said last-mentioned means includes a cam element on said carriage and a cooperating cam element on said pulley.
 13. Apparatus according to claim 12 including an air cylinder biasing said carriage against the tension in the web, and a pressure regulator for maintaining the pressure in said cylinder constant at all times. 